Department of Mechanical Engineering

Automobile Engine Design– 16 ME 4072

LAB Manual

ID Number
Name
Year and Semester
Academic Year
ID No.: 16ME4072 Exp. No.:

Declaration

I, Mr. P.Prithvi Raj as a course coordinator, here by declare, “None of the

experiments mentioned in their lab manual are repeated in any other course of this

batch of students” for the subject AUTOMOBILE ENGINE DESIGN-

16ME4072.

Course Coordinator
ID No.: 16ME4072 Exp. No.:

CERTIFICATE

This is to certify that this is the bonafied work carried out

by
Mr. bearing the
Regd.No of IV year B. Tech II semester in Mechanical
engineering for the Technical course in Automobile Engine Design during the
academic year 2019-2020.

No of Experiment Done:

Total marks gained:

Signature of the faculty Incharge Head of the Department

ID No.: 16ME4072 Exp. No.:

Lab Assessment for Automobile Engine Design
MARKS
Name of the
ExptNo. Date Record Result/& Inference Viva Total Signature
experiment
(5M) Graphs & Voce marks of faculty
(5M) Analysis (20M) with date
(5M) (5M)

10

11

12

13

Total :
NOTE: Teacher must maintain the same format in the attendance register of the said
lab
course
ID No.: 16ME4072 Exp. No.:

S.No. List of Experiments Signature with date

1 Modeling of Piston and its components

2 Modeling of Engine Valve (Poppet Value)

3 Modeling Petrol Engine Connecting Rod

4 Modeling of Rocker arm

5 Modeling of Fuel Injection

6 Modeling of Petrol Engine Spark Plug

7 Modeling of Radial Engine Cylinder head

8 Modeling of Turbo Charger Impeller

9 Static Analysis of Engine Valve

10 Static Analysis of Piston Head

11 Case Study

12 Modeling of Engine Crank Shaft

ID No.: 16ME4072 Exp. No.:

KLEF
Department of Mechanical Engineering
AUTOMOBILE ENGINE DESIGN

Lab experiment-1
Piston and its components

Aim: To do model, assemble and do static analysis on the given model using CAD platform.
Software used: CATIA V5/ Solid Works
Software tools: Extrude, Revolve, Pocket, Mirror.
Dimensions of the Component

Procedure:
Step1: Open windows select new part model to enter the 3D interface.
Step2: Identify the complicated design of the given figure to start the 2D model.
Step3: Ensure all the dimensions used for the development of the 2D model.
Step4: Select an appropriate plane to (xy, yz, zx) to enter to sketcher module.
Step5: Use line, circle, rectangular etc., tools to develop the 2D model
Step6: Use dimensional constrain tool to dimension the entire developed model.
Step7: Select on exit workbench tool to develop the 3D model for the 2D sketch.
Step8: Selecting solid component tools like pad, revolve and multi section to develop the solid
component.
Step 9: Using different transformation tools develop the given 3D model.
Step 10: Repeat step 2 to step 9 for all other components.
Inference/Analysis: A piston is a component of reciprocating engines, reciprocating pumps, gas
compressors and pneumatic cylinders, among other similar mechanisms. It is the moving
component that is contained by a cylinder and is made gas-tight by piston rings.
ID No.: 16ME4072 Exp. No.:

Component designed in Catia V5

Result: The given component is modeled using design software with appropriate dimension.
ID No.: 16ME4072 Exp. No.:

KLEF
Department of Mechanical Engineering
AUTOMOBILE ENGINE DESIGN

Lab experiment-2
Engine Valve (Poppet Value)

Aim: To model and assemble the given components using CAD software
Software used: CATIA V5/ Solid Works
Software tools: Extrude, Revolve, Pocket, Mirror.
Dimensions of the Component:

Inlet/Outlet Port Valve

Procedure:
Step1: Open windows select new part model to enter the 3D interface.
Step2: Identify the complicated design of the given figure to start the 2D model.
Step3: Ensure all the dimensions used for the development of the 2D model.
Step4: Select an appropriate plane to (xy, yz, zx) to enter to sketcher module.
Step5: Use line, circle, rectangular etc., tools to develop the 2D model
Step6: Use dimensional constrain tool to dimension the entire developed model.
Step7: Select on exit workbench tool to develop the 3D model for the 2D sketch.
Step8: Selecting solid component tools like pad, revolve and multi section to develop the solid
component.
Step 9: Using different transformation tools develop the given 3D model.
Step 10: Repeat step 2 to step 9 for all other components.
ID No.: 16ME4072 Exp.
No.:

Inference/Analysis: A poppet valve (also called mushroom valve) is a valve typically used to
control the timing and quantity of gas or vapor flow into an engine. It consists of a hole, usually
round or oval, and a tapered plug, usually a disk shape on the end of a shaft also called
a valve stem.

Component designed in Catia V5

Result: The given component is modeled using design software with appropriate dimension.
ID No.: 16ME4072 Exp. No.:

KLEF
Department of Mechanical Engineering
AUTOMOBILE ENGINE DESIGN

Lab experiment-3
Petrol Engine Connecting Rod

Aim: To model a given component using CAD software

Software used: CATIA V5/ Solid Works
Software tools: Extrude, Revolve, Pocket, Mirror, Fillet, chamfer, hole.
Dimensions of the Component:

Procedure:
Step1: Open windows select new part model to enter the 3D interface.
Step2: Identify the complicated design of the given figure to start the 2D model.
Step3: Ensure all the dimensions used for the development of the 2D model.
Step4: Select an appropriate plane to (xy, yz, zx) to enter to sketcher module.
Step5: Use line, circle, rectangular etc., tools to develop the 2D model
Step6: Use dimensional constrain tool to dimension the entire developed model.
ID No.: 16ME4072 Exp.
No.:

Step7: Select on exit workbench tool to develop the 3D model for the 2D sketch.
Step8: Selecting solid component tools like pad, revolve and multi section to develop the solid
component.
Step 9: Using different transformation tools develop the given 3D model.
Step 10: Repeat step 2 to step 9 for all other components.

Inference/Analysis: A connecting rod is a rigid member, which connects a piston to a crank or

crankshaft in a reciprocating engine. Together with the crank, it forms a simple mechanism that
converts reciprocating motion into rotating motion. A connecting rod may also convert rotating
motion into reciprocating motion, its original use.

Component designed in Catia V5

Result: The given component is modeled using design software with appropriate dimension.
ID No.: 16ME4072 Exp. No.:

KLEF
Department of Mechanical Engineering
AUTOMOBILE ENGINE DESIGN

Lab experiment-4
Rocker arm

Aim: To model a given component using CAD software

Software used: CATIA V5/ Solid Works
Software tools: Extrude, Revolve, Pocket, Mirror, Fillet, chamfer, hole.

Dimensions of the Component:

Rocker Arm

Procedure:
Step1: Open windows select new part model to enter the 3D interface.
Step2: Identify the complicated design of the given figure to start the 2D model.
Step3: Ensure all the dimensions used for the development of the 2D model.
Step4: Select an appropriate plane to (xy, yz, zx) to enter to sketcher module.
Step5: Use line, circle, rectangular etc., tools to develop the 2D model
Step6: Use dimensional constrain tool to dimension the entire developed model.
Step7: Select on exit workbench tool to develop the 3D model for the 2D sketch.
Step8: Selecting solid component tools like pad, revolve and multi section to develop the solid
component.
Step 9: Using different transformation tools develop the given 3D model.
Step 10: Repeat step 2 to step 9 for all other components.

Inference/Analysis:
A rocker arm (in the context of an internal combustion engine of automotive,
marine, motorcycle and reciprocating aviation types) is an oscillating lever that conveys radial
movement from the cam lobe into linear movement at the poppet valve to open it.
ID No.: 16ME4072 Exp. No.:

Component made in CATIA V5

Result: The given component is modeled using design software with appropriate dimension.
ID No.: 16ME4072 Exp. No.:

KLEF
Department of Mechanical Engineering
AUTOMOBILE ENGINE DESIGN

Lab experiment-5
Fuel Injection

Aim: To model a given component using CAD software

Software used: CATIA V5/ Solid Works
Software tools: Extrude, Revolve, Pocket, Mirror, Fillet, chamfer, hole.

Dimensions of the Component:

Fuel Injection System

Procedure:
Step1: Open windows select new part model to enter the 3D interface.
Step2: Identify the complicated design of the given figure to start the 2D model.
Step3: Ensure all the dimensions used for the development of the 2D model.
Step4: Select an appropriate plane to (xy, yz, zx) to enter to sketcher module.
Step5: Use line, circle, rectangular etc., tools to develop the 2D model
Step6: Use dimensional constrain tool to dimension the entire developed model.
Step7: Select on exit workbench tool to develop the 3D model for the 2D sketch.
Step8: Selecting solid component tools like pad, revolve and multi section to develop the solid
component.
Step 9: Using different transformation tools develop the given 3D model.
Step 10: Repeat step 2 to step 9 for all other components.
ID No.: 16ME4072 Exp.
No.:

Inference/Analysis: The fuel injector, an electrically operated gate, delivers fuel into the engine
via its nozzle. The Engine Control Unit (ECU) dictates when the injector should inject fuel into
the engine cylinder. It is advisable to clean the injectors every 25,000 to 30,000 miles to ensure
that they do not get clogged.

Component designed in Catia V5

Result: The given component is modeled using design software with appropriate dimension.
ID No.: 16ME4072 Exp. No.:

KLEF
Department of Mechanical Engineering
AUTOMOBILE ENGINE DESIGN

Lab experiment-6
Spark Plug

Aim: To model a given component using CAD software

Software used: CATIA V5/ Solid Works
Software tools: Extrude, Revolve, Pocket, Mirror, Fillet, chamfer, hole.
Dimensions of the Component: Assume the dimensions according to the given dimensions

Procedure:
Step1: Open windows select new part model to enter the 3D interface.
Step2: Identify the complicated design of the given figure to start the 2D model.
Step3: Ensure all the dimensions used for the development of the 2D model.
Step4: Select an appropriate plane to (xy, yz, zx) to enter to sketcher module.
Step5: Use line, circle, rectangular etc., tools to develop the 2D model
Step6: Use dimensional constrain tool to dimension the entire developed model.
Step7: Select on exit workbench tool to develop the 3D model for the 2D sketch.
ID No.: 16ME4072 Exp.
No.:

Step8: Selecting solid component tools like pad, revolve and multi section to develop the solid
component.
Step 9: Using different transformation tools develop the given 3D model.
Step 10: Repeat step 2 to step 9 for all other components.

Inference/Analysis: The spark plug has two primary functions: To ignite the air/fuel mixture.
Electrical energy is transmitted through the spark plug, jumping the gap in the plugs firing end
if the voltage supplied to the plug is high enough. This electrical spark ignites the gasoline/air
mixture in the combustion chamber.

Result: The given component is modeled using design software with appropriate dimension.
ID No.: 16ME4072 Exp. No.:

KLEF
Department of Mechanical Engineering
AUTOMOBILE ENGINE DESIGN

Lab experiment-7
Radial Engine Cylinder head

Aim: To model a given component using CAD software

Software used: CATIA V5/ Solid Works
Software tools: Extrude, Revolve, Pocket, Mirror, Fillet, chamfer, hole.
Dimensions of the Component:

Procedure:
Step1: Open windows select new part model to enter the 3D interface.
Step2: Identify the complicated design of the given figure to start the 2D model.
Step3: Ensure all the dimensions used for the development of the 2D model.
Step4: Select an appropriate plane to (xy, yz, zx) to enter to sketcher module.
Step5: Use line, circle, rectangular etc., tools to develop the 2D model
Step6: Use dimensional constrain tool to dimension the entire developed model.
Step7: Select on exit workbench tool to develop the 3D model for the 2D sketch.
Step8: Selecting solid component tools like pad, revolve and multi section to develop the solid
component.
Step 9: Using different transformation tools develop the given 3D model.
Step 10: Repeat step 2 to step 9 for all other components.
ID No.: 16ME4072 Exp.
No.:

Inference/Analysis: In an internal combustion engine, the cylinder head (often informally

abbreviated to just head) sits above the cylinders on top of the cylinder block. It closes in the
top of the cylinder, forming the combustion chamber. A head gasket seals this joint.

Result: The given component is modeled using design software with appropriate dimensio
ID No.: 16ME4072 Exp. No.:

KLEF
Department of Mechanical Engineering
AUTOMOBILE ENGINE DESIGN

Lab experiment-9
Static Analysis of Engine Valve

Aim: To do static analysis on the given model using CAD platform.

Software used: CATIA V5/ Solid Works
Software tools: Extrude, Revolve, Pocket, Mirror, Fillet, chamfer, hole.
Dimensions of the Component

Procedure:

• Before you begin:

1. Select the part in the specification tree.

2. Click the Apply Material icon.
3. The Material library appears.
4. Select a material family, then select the desired material from the displayed list,
5. Then click OK.
The material is applied.

• You can visualize the material properties and its analysis characteristics by selecting
the material in the specification tree and using Edit -> Properties -> Analysis.
ID No.: 16ME4072 Exp. No.:

• If you select Start->Analysis & Simulation -> Generative Structural Analysis from a CAT
Part document containing a part without any material assigned, the material library
will appear directly for an easy material selection.
• Open the CAT Part Document.
For this, select File -> Open, and then select the desired. CAT Part file.
• Define the View Mode.
For this, select the View -> Render Style -> Customize View menu.
• The Custom View Modes dialog appears: activate the Shading option and then the Materials
option in the Custom View Modes dialog box.
• Enter Generative Structural Analysis Workbench.

Select Start -> Analysis & Simulation -> Generative Structural Analysis from the menu bar.

• The New Analysis Case dialog box appears with Static Analysis as default option.
• Static Analysis means that you will analyze the static boundary conditions of the CATA
analysis document one after the other.

• Frequency Analysis means that you will analyze the dynamic boundary conditions of the
CATA analysis document.
• Free Frequency Analysis means that you will analyze the buckling dynamic conditions of
the CATA analysis document.
• Keep as default starting analysis case means that when you next open the Generative
Structural Analysis workbench from the menu bar, the selected case appears as default.

Select an Analysis Case type in the New Analysis Case dialog box.

In this particular case, also keep Static Analysis type selected.

Click OK in the New Analysis Case dialog box to enter the workbench.

• Click the Displacement icon in the Image toolbar.

A plot of the displacement field is displayed with arrow symbols. If you go over the plot
with the cursor, you can visualize the nodes. The computed displacement field can now
be used to compute other results such as strains, stresses, reaction forces and so forth.

• Go to View -> Render Style -> Customize View and make sure the Materials option is active
in the Custom View Modes dialog box.
• Double-click the Von Misses Stress (nodal value) object in the specification tree to edit the
image. The Image Edition dialog box appears.
• Click the Image Extrema icon in the Analysis Tools toolbar to obtain local and global
extrema values of the von Misses stress field magnitude.
• Click OK once you have defined the number of the extrema you need. In this particular case,
you will define that you need two Absolute extrema.
• Locations of the global maxima and minima are indicated on the image, and the Extreme
object appears in the specification tree under the Static Case Solutions objects set.
ID No.: 16ME4072 Exp.
No.:

Inference:
Finite Element analysis is a method that helps to simulate mechanical parts and systems to get
information about failure, deformation and stresses under some various kinds of loadings.

Result: The given component is modeled using design software with appropriate dimension and
analyzed the failure analysis of the component developing the von misses stresses
and deformations.
ID No.: 16ME4072 Exp. No.:

KLEF
Department of Mechanical Engineering
AUTOMOBILE ENGINE DESIGN

Lab experiment-10
Static Analysis of Piston Head

Aim: To do model, assemble and do static analysis on the given model using CAD platform.
Software used: CATIA V5/ Solid Works
Software tools: Extrude, Revolve, Pocket, Mirror.

Dimensions of the Component

Procedure:
Step1: Open windows select new part model to enter the 3D interface.
Step2: Identify the complicated design of the given figure to start the 2D model.
Step3: Ensure all the dimensions used for the development of the 2D model.
Step4: Select an appropriate plane to (xy, yz, zx) to enter to sketcher module.
Step5: Use line, circle, rectangular etc., tools to develop the 2D model
Step6: Use dimensional constrain tool to dimension the entire developed model.
Step7: Select on exit workbench tool to develop the 3D model for the 2D sketch.
Step8: Selecting solid component tools like pad, revolve and multi section to develop the solid
component.
Step 9: Using different transformation tools develop the given 3D model.
Step 10: Repeat step 2 to step 9 for all other components.
ID No.: 16ME4072 Exp. No.:

• Before you begin:

6. Select the part in the specification tree.

7. Click the Apply Material icon.
8. The Material library appears.
9. Select a material family, then select the desired material from the displayed list,
10. Then click OK.
The material is applied.

• You can visualize the material properties and its analysis characteristics by selecting
the material in the specification tree and using Edit -> Properties -> Analysis.
• If you select Start->Analysis & Simulation -> Generative Structural Analysis from a CAT
Part document containing a part without any material assigned, the material library
will appear directly for an easy material selection.
• Open the CAT Part Document.
For this, select File -> Open, and then select the desired. CAT Part file.
• Define the View Mode.
For this, select the View -> Render Style -> Customize View menu.
• The Custom View Modes dialog appears: activate the Shading option and then the Materials
option in the Custom View Modes dialog box.
• Enter Generative Structural Analysis Workbench.

Select Start -> Analysis & Simulation -> Generative Structural Analysis from the menu bar.

• The New Analysis Case dialog box appears with Static Analysis as default option.
• Static Analysis means that you will analyze the static boundary conditions of the CATA
analysis document one after the other.

• Frequency Analysis means that you will analyze the dynamic boundary conditions of the
CATA analysis document.
• Free Frequency Analysis means that you will analyze the buckling dynamic conditions of
the CATA analysis document.
• Keep as default starting analysis case means that when you next open the Generative
Structural Analysis workbench from the menu bar, the selected case appears as default.

Select an Analysis Case type in the New Analysis Case dialog box.

In this particular case, also keep Static Analysis type selected.

Click OK in the New Analysis Case dialog box to enter the workbench.

• Click the Displacement icon in the Image toolbar.

A plot of the displacement field is displayed with arrow symbols. If you go over the plot
with the cursor, you can visualize the nodes. The computed displacement field can now
be used to compute other results such as strains, stresses, reaction forces and so forth.
ID No.: 16ME4072 Exp. No.:

• Go to View -> Render Style -> Customize View and make sure the Materials option is active
in the Custom View Modes dialog box.
• Double-click the Von Misses Stress (nodal value) object in the specification tree to edit the
image. The Image Edition dialog box appears.
• Click the Image Extrema icon in the Analysis Tools toolbar to obtain local and global
extrema values of the von Misses stress field magnitude.
• Click OK once you have defined the number of the extrema you need. In this particular case,
you will define that you need two Absolute extrema.
• Locations of the global maxima and minima are indicated on the image, and the Extreme
object appears in the specification tree under the Static Case Solutions objects set.

Inference/Analysis: A piston is a component of reciprocating engines, reciprocating pumps, gas

compressors and pneumatic cylinders, among other similar mechanisms. It is the moving
component that is contained by a cylinder and is made gas-tight by piston rings.
Component designed in Catia V5
ID No.: 16ME4072 Exp. No.:

Result: The given component is modeled using design software with appropriate dimension and
analyzed the failure analysis of the component developing the von misses stresses
and deformations.
ID No.: 16ME4072 Exp. No.:

Format for developing the Case study for AED lab

Experiment 11

Case study 1: Study of 6 Cylinder radial and V6 engine.

This must be based on an Engine manual of any one recent trend vehicle to be consolidated with
the problem and its solution to reduce the maintenance issues.

References:
1. https://www.india.ford.com/owner/owner-manual/#
2. https://www.volkswagen.co.uk/owners/manuals
ID No.: 16ME4072 Exp. No.:

KLEF
Department of Mechanical Engineering
AUTOMOBILE ENGINE DESIGN
Lab experiment-12
Modeling of Crank Shaft

Aim: To model a given component using CAD software

Software used: CATIA V5/ Solid Works
Software tools: Extrude, Revolve, Pocket, Mirror, Fillet, chamfer, hole.
Dimensions of the Component: Assume the dimensions according to the given dimensions

Procedure:
Step1: Open windows select new part model to enter the 3D interface.
Step2: Identify the complicated design of the given figure to start the 2D model.
Step3: Ensure all the dimensions used for the development of the 2D model.
Step4: Select an appropriate plane to (xy, yz, zx) to enter to sketcher module.
Step5: Use line, circle, rectangular etc., tools to develop the 2D model
Step6: Use dimensional constrain tool to dimension the entire developed model.
Step7: Select on exit workbench tool to develop the 3D model for the 2D sketch.
Step8: Selecting solid component tools like pad, revolve and multi section to develop the solid
component.
Step 9: Using different transformation tools develop the given 3D model.
Step 10: Repeat step 2 to step 9 for all other components.

Inference/Analysis: The spark plug has two primary functions: To ignite the air/fuel mixture.
Electrical energy is transmitted through the spark plug, jumping the gap in the plugs firing end
if the voltage supplied to the plug is high enough. This electrical spark ignites the gasoline/air
mixture in the combustion chamber.
ID No.: 16ME4072 Exp. No.:

Result: The given component is modeled using design software with appropriate dimension.